Composite flooring for recreational vehicles

ABSTRACT

A laminated panel is provided comprising a skeletal framework, foam core inserts, an impact resistant sheet, and a weather resistant sheet bonded together with adhesive. Recreational vehicles incorporating such panels are also contemplated, as are methods of making the composite laminated panel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in part of U.S. patent applicationSer. No. 17/836,207 filed Jun. 9, 2022, which is a continuation of U.S.patent application Ser. No. 16/815,780 filed Mar. 11, 2020, now U.S.Pat. No. 11,383,768, which claims the benefit of U.S. ProvisionalApplication No. 62/817,238, filed Mar. 12, 2019, which are incorporatedby reference herein in their entirety.

BACKGROUND

The present disclosure is directed to recreational vehicles including,but not limited to trailers and mobile homes.

BRIEF SUMMARY

The present disclosure is directed to composite laminated panels for usein the construction of floors, walls, ceilings and other portions ofrecreational vehicles and, in one embodiment, to an improved flooringsystem made of composite laminated panels for use in recreationalvehicles. Conventional flooring systems are wood-based and, uponexposure to moisture, are susceptible to rotting, swelling, odordevelopment, discoloration, or formation of mold. The present inventorshave formulated a composite flooring that meets the requirements ofautomotive and/or commercial grade compressive strength and point loadstrength, as applicable for recreational vehicles that is notsusceptible to rotting, swelling, odor development, discoloration, orformation of mold.

The improved flooring system of the present disclosure, which does notmake substantial use of wood products, may be conveniently secured to orotherwise installed over the chassis or other frame components ofrecreational vehicles. The composite laminated panels of the improvedflooring system may also be conveniently installed with a seamlessconstruction and employ materials that provide fastener retentionproperties that are comparable to those provided by conventionalwood-based flooring systems, which typically include Lauan, Plyveneer,and other wood-based products.

In accordance with one embodiment of the present disclosure, arecreational vehicle comprises a chassis, at least one axle assembly, avehicle body, and a composite floor. The vehicle body and the compositefloor are supported by the chassis. The axle assembly is coupled to thechassis and provides motive support and underbody clearance to thechassis. The composite floor comprises a skeletal framework, a pluralityof foam core inserts, an impact resistant sheet on an interior side ofthe composite floor, a weather resistant sheet on an exterior side ofthe composite floor, a plurality of contained framework cells, and astructural adhesive. The skeletal framework of the composite floorcomprises a plurality of closed frame sections defined by frame segmentsof the skeletal framework. Each contained framework cell is boundedvolumetrically by frame segments of a closed frame section, portions ofthe impact resistant sheet, and portions of the weather resistant sheet.Each of the foam core inserts is large enough to frictionally engage atleast two parallel frame segments of a closed frame section of theskeletal framework. Each contained framework cell is packed with one ormore of the foam core inserts and the foam core inserts within each cellcollectively occupy a substantial entirety of the contained frameworkcell. The structural adhesive is arranged to bond the skeletalframework, the foam core inserts, the impact resistant sheet, and theweather-resistant sheet as a structurally integrated composite floorwhere a force exerted on the impact resistant sheet in a direction of acontained framework cell encounters resistance that is collectivelyattributable to one or more of the foam core inserts, one or more of theframe segments of the skeletal framework, and the weather resistantsheet, such that a collective modulus of elasticity (MOE) of thecomposite floor comprises modulus components that are attributable tothe skeletal framework, the foam core inserts, the impact resistantsheet, and the weather resistant sheet.

In accordance with another embodiment of the present disclosure, amethod of making a composite floor comprises forming a skeletalframework by assembling a plurality of closed frame sections defined byframe segments, inserting one or more foam core inserts into each of theclosed frame sections of the skeletal framework, providing an impactresistant sheet and a weather resistant sheet, each sheet having aninternal side and an external side, applying a structural adhesive tothe internal side of the impact resistant sheet and contacting theimpact resistant sheet with the skeletal framework and foam coreinserts, applying the structural adhesive to the internal side of theweather resistant sheet and contacting the weather resistant sheet withthe skeletal framework and foam core inserts, enclosing a compositefloor assembly comprising the skeletal framework, foam core inserts,structural adhesive, impact resistant sheet, and weather resistant sheetin a vacuum bag assembly, evacuating the vacuum bag assembly of air tocompress the composite floor assembly, maintaining a vacuum environmentin the vacuum bag assembly to bond each of the impact resistant sheetand the weather resistant sheet to the skeletal framework and foam coreinserts, returning air to the vacuum bag assembly, and removing thecomposite floor from the vacuum bag assembly.

Although the concepts of the present disclosure are described hereinwith primary reference to floor construction in recreational vehicles,it is contemplated that the concepts will enjoy applicability to anystructural component of a trailer, vehicle, or other application. Forexample, and not by way of limitation, it is contemplated that theconcepts of the present disclosure will enjoy applicability to mobilehomes.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following detailed description of specific embodiments of thepresent disclosure can be best understood when read in conjunction withthe following drawings, where like structure is indicated with likereference numerals and in which:

FIG. 1 is a schematic illustration of a recreational vehicle accordingto one embodiment of the present disclosure;

FIG. 2 is a schematic illustration of a skeletal framework of acomposite floor according to one embodiment of the present disclosure;

FIG. 2A is a schematic illustration of one closed frame section of askeletal framework of a composite floor according to one embodiment ofthe present disclosure; and

FIG. 3 is a schematic illustration of the components of a compositefloor according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

FIG. 1 illustrates a recreational vehicle 100 comprising a chassis 102,at least one axle assembly 104, a vehicle body 106, and a compositefloor 108. With additional reference to FIGS. 2 and 3 , the compositefloor 108 comprises a skeletal framework 110, a plurality of foam coreinserts 112, an impact resistant sheet 114 on an interior side of thecomposite floor 108, a weather resistant sheet 116 on an exterior sideof the composite floor 108, a plurality of contained framework cells218, and a structural adhesive 320. The skeletal framework 110 of thecomposite floor 108 comprises a plurality of closed frame sections 222defined by frame segments 124 of the skeletal framework 110. FIG. 1 ispresented for illustrative purposes only and it is noted that theconcepts of the present disclosure are not limited to the specificsystem configurations illustrated therein.

Referring now to FIGS. 1 and 2 , the vehicle body 106 and the compositefloor 108 may be supported by the chassis 102. The axle assembly 104 maybe coupled to the chassis 102 and provides motive support and underbodyclearance to the chassis 102. Each contained framework cell may bebounded volumetrically by frame segments 124 of a closed frame section222, portions of the impact resistant sheet 114, and portions of theweather resistant sheet 116. Each of the foam core inserts 112 may belarge enough to frictionally engage at least two parallel frame segments124 of a closed frame section 222 of the skeletal framework 110. Eachcontained framework cell 218 may be packed with one or more of the foamcore inserts 112 and the foam core inserts 112 within each cell maycollectively occupy a substantial entirety of the contained frameworkcell 218.

With reference again to FIG. 3 , the structural adhesive 320 may bearranged to bond the skeletal framework 110, the foam core inserts 112,the impact resistant sheet, and the weather-resistant sheet as astructurally integrated composite floor 108 where a force exerted on theimpact resistant sheet in a direction of a contained framework cell 218encounters resistance that may be collectively attributable to one ormore of the foam core inserts 112, one or more of the frame segments 124of the skeletal framework 110, and the weather resistant sheet, suchthat a collective modulus of elasticity (MOE) of the composite floor 108comprises modulus components that may be attributable to the skeletalframework 110, the foam core inserts 112, the impact resistant sheet114, and the weather resistant sheet 116.

The collective MOE of the composite floor 108 may be between about 6000ksi (4×10⁴ MPa) and about 10000 ksi (7×10⁴ MPa). The collective MOE ofthe composite floor 108 may be 8000 ksi (5.5×10⁴ MPa)±10%.

Referring now to FIGS. 1 and 2 , a majority of the closed frame sections222 of the skeletal framework 110 comprise a planar area of betweenapproximately 1.5 m² and approximately 3.5 m², which is significantlylarger than would be available in an aluminum frame composite floorconstructed in a different manner, using different materials, like thinplywood and relatively low density foam. Although larger area sections222 are contemplated, typically, the closed frame sections 222 of theskeletal framework 110 will comprise a maximum planar area of less thanapproximately 6.0 m². Similarly, although smaller area sections arecontemplated, typically, a majority of the closed frame sections 222 ofthe skeletal framework 110 will comprise a planar area that exceedsapproximately 1.0 m².

Referring further to FIGS. 1 and 2 , a majority of the closed framesections 222 of the skeletal framework 110 will comprise an unsupportedlongitudinal span of between approximately 1.5 m and approximately 4.0m, which is significantly larger than would be available in an aluminumframe composite floor constructed in a different manner, using differentmaterials, like thin plywood and relatively low density foam. Althoughlarger spans are contemplated, typically, the closed frame sections 222of the skeletal framework 110 will comprise a maximum unsupportedlongitudinal span of less than approximately 5.0 m. Similarly, althoughsmaller spans are contemplated, a majority of the closed frame sections222 of the skeletal framework 110 will comprise a minimum unsupportedlongitudinal span that exceeds approximately 1.0 m. As used herein, theterm “longitudinal” is used to indicate the direction parallel to thelongest pair of frame segments 124 in a particular closed frame section222.

A plurality of the plurality of closed frame sections 222 may lie in acommon plane. At least one additional closed frame section 222 may liein a plane parallel to the common plane. The composite floor 108 maycomprise a plurality of closed frame sections 222 and at least one openframe section.

Each of the plurality of foam core inserts 112 may comprise a density ofat least about 30 kg/m³±10%. In some embodiments, each of the pluralityof foam core inserts comprises a density of between about 30 kg/m³±10%and about 50 kg/m³±10%. Each of the plurality of foam core inserts 112may frictionally engage at least two pairs of parallel frame segments124 of a closed frame section 222 of the skeletal framework 110. Eachcontained framework cell 218 may be packed with a single foam coreinsert 112 that occupies a substantial entirety of the containedframework cell 218. Each contained framework cell 218 may be packed witha plurality of foam core inserts 112 that collectively occupy asubstantial entirety of the contained framework cell 218. A foamthickness defined by the one or more foam core inserts 112 packed in acontained framework cell 218 may be equal to a frame thickness of theframe segments 124 of the closed frame section 222 bounding thecontained framework cell. A foam thickness defined by the one or morefoam core inserts 112 packed in a contained framework cell 218 may begreater than or less than a frame thickness of the frame segments 124 ofthe closed frame section 222 bounding the contained framework cell 218.

In some embodiments, each of the plurality of foam core inserts 112 maybe sized to fit into a closed frame section 222 of the skeletalframework 110, or, in the alternative, each of the plurality of foamcore inserts 112 may be formed in-situ in each closed frame section 222of the skeletal framework 110.

Again referring to FIG. 3 , the structural adhesive 320 may be arrangedto bond the skeletal framework 110, the foam core inserts 112, theimpact resistant sheet 114, and the weather resistant sheet 116 todefine a total composite floor 108 thickness. The impact resistant sheet114 and the weather resistant sheet 116 may account for less than 20% ofthe total composite floor 108 thickness. The weather resistant sheet 116may be characterized by an average sheet thickness that is less than anaverage sheet thickness of the impact resistant sheet 114 and by an areadensity that is less than 50% of an area density of the impact resistantsheet 114.

Returning to FIGS. 1 and 2 , the sheet thickness of the impact resistantsheet 114 may be 4.00 mm±20%. The sheet thickness of the weatherresistant sheet 116 may be 2.7 mm±10%. The area density of the impactresistant sheet 114 may be 2850 g/m²±10%. The area density of theweather resistant sheet 116 may be 1000 g/m²±10%.

The impact resistant sheet 114 and the weather resistant sheet 116 maybe fiberglass reinforced polymer sheets. The fiber content of the impactresistant sheet 114 and the weather resistant sheet 116 may be betweenabout 35 wt. % and about 70 wt. %. The impact resistant sheet 114 maycomprise a greater fiber content than the weather resistant sheet 116.The impact resistant sheet 114 and the weather resistant sheet 116 maydefine a fiber content A, representing a difference between a fiber wt.% content of the impact resistant sheet 114 and a fiber wt. % content ofthe weather resistant sheet 116 that may be at least 20 wt. %. Theimpact resistant sheet 114 may comprise a fiber content of about 60 wt.% and the weather resistant sheet 116 may comprise a fiber content ofabout 40 wt. %. For example, in some embodiments, the impact resistantsheet 114 may comprise a fiber content of 64.5 wt. %±2% and the weatherresistant sheet 116 may comprise a fiber content of about 42 wt. %±2%.

The impact resistant sheet 114 has a relatively high compressionstrength and point load characteristics. The impact resistant sheet 114is suitable for supporting interior components of a recreational vehicle100 and heavy foot traffic. In some embodiments, the impact resistantsheet 114 may be a multi-layered, fiber-reinforced laminate comprising afirst layer fabricated from a thermoplastic composite comprisingpolypropylene resin reinforced with continuous bi-directional glassfibers, a second layer fabricated from a thermoplastic compositecomprising polypropylene resin reinforced with short strand X-Y-Zoriented glass fibers that may be weaved and needled to orient the glassfibers along the three-dimensional axes, a third layer like the firstlayer, and a woven, adhesion-promoting scrim layer, which may be adheredto the foam core inserts 112. The scrim layer may be provided in avariety of forms including, for example, a resin-impregnated non-wovenmat of randomly-oriented fibers. The fibers may be carbon fibers, glassfibers, or synthetic resin fibers. For example, some synthetic fibersthat may be used include aramid fibers. The fibers of the scrim layermay also be inorganic fibers such as metal fibers. For example, somemetal fibers that may be used include aluminum fibers or titaniumfibers.

It should be noted that the composition of the weather resistant sheet116 may differ from the impact resistant sheet 114. Some of thefunctional requirements of the weather resistant sheet 116 differ fromthose of the impact resistant sheet 114. For instance, the weatherresistant sheet 116 will be exposed to the exterior environment and, assuch, may be more environmentally durable than the impact resistantsheet 114. In some embodiments, the weather resistant sheet 116 maycomprise a single polypropylene resin layer reinforced with long strandglass fibers and an adhesion-promoting scrim layer between thereinforced resin layer and the foam core inserts 112. The weatherresistant sheet 116 may also be provided with a thin protective film onits exterior-facing side to enhance resistance to moisture and otherenvironmental elements.

Again referring to FIG. 3 , the structural adhesive 320 may comprisecontinuous or discontinuous layers of adhesive between the skeletalframework 110 and the foam core inserts 112 and (i) the impact resistantsheet 114, (ii) the weather resistant sheet 116, or (iii) both.

It is envisioned that, in some embodiments, the composite floor may bebonded with or without the presence additional intervening materialsarranged between the impact resistant sheet and the foam core inserts,as well as between the weather resistant layer and the foam coreinserts. It is envisioned that such additional intervening materials mayfurther promote adhesion, further enhance structural integrity, or serveany other purpose.

Referring again to FIG. 1 , the recreational vehicle 100 may be atowable trailer or a motorized recreational vehicle, such as amotorhome, a fifth wheel camper, a toy hauler, a travel trailer, ateardrop camper, a tiny trailer, a pop-up camper, or any otherrecreational vehicle. The axle assembly 104 may be a driven ornon-driven axle assembly.

With reference to FIGS. 1-3 , in another embodiment, a method of makinga composite floor 108 comprises forming a skeletal framework 110 byassembling a plurality of closed frame sections 222 defined by framesegments 124, inserting one or more foam core inserts 112 into each ofthe closed frame sections of the skeletal framework 110, providing animpact resistant sheet 114 and a weather resistant sheet 116, each sheethaving an internal side and an external side, applying a structuraladhesive 320 to the internal side of the impact resistant sheet 114 andcontacting the impact resistant sheet 114 with the skeletal framework110 and foam core inserts 112, applying the structural adhesive 320 tothe internal side of the weather resistant sheet 116 and contacting theweather resistant sheet 116 with the skeletal framework 110 and foamcore inserts 112, enclosing a composite floor assembly comprising theskeletal framework 110, foam core inserts 112, structural adhesive 320,impact resistant sheet 114, and weather resistant sheet 116 in a vacuumbag assembly, evacuating the vacuum bag assembly of air to compress thecomposite floor assembly, maintaining a vacuum environment in the vacuumbag assembly to bond each of the impact resistant sheet 114 and theweather resistant sheet 116 to the skeletal framework 110 and foam coreinserts 112, returning air to the vacuum bag assembly, and removing thecomposite floor 108 from the vacuum bag assembly.

For the purposes of defining and describing the present invention, it isnoted that the impact resistant sheet 114 is “impact resistant” in thesense that it is sufficiently rigid to protect the foam core inserts 112from the impact of foot traffic in the interior of the vehicle, withoutan accompanying layer of carpet padding, carpeting, or other interiorfloor components.

Each closed frame section 222 of the skeletal framework 110 is packedwith at least one of the plurality of foam core inserts 112. For thepurposes of the present disclosure it is noted that the term “packed”denotes the insertion of a foam core insert 112 into the volume of spacedefined by a closed frame section 222, with the understanding that thefoam core insert 112 may occupy all or part of the volume, and mayextend beyond the volume of the space defined by the closed framesection 222.

The adhesive is described herein as being “structural” only in the sensethat it enables the other components of the composite floor 108 tocontribute to the collective rigidity of the composite floor 108.

It is noted that terms like “preferably,” “commonly,” and “typically,”when utilized herein, are not utilized to limit the scope of the claimedinvention or to imply that certain features are critical, essential, oreven important to the structure or function of the claimed invention.Rather, these terms are merely intended to identify particular aspectsof an embodiment of the present disclosure or to emphasize alternativeor additional features that may or may not be utilized in a particularembodiment of the present disclosure.

For the purposes of describing and defining the present invention it isnoted that the terms “substantially” and “approximately” are utilizedherein to represent the inherent degree of uncertainty that may beattributed to any quantitative comparison, value, measurement, or otherrepresentation. The terms “substantially” and “approximately” are alsoutilized herein to represent the degree by which a quantitativerepresentation may vary from a stated reference without resulting in achange in the basic function of the subject matter at issue. Forexample, reference herein to a foam core insert 112 that occupies a“substantial” entirety of an open section volume is intended to coverinstances where quantitatively or functionally insignificant portions ofthe open section volume are not occupied by the foam core insert 112.

Having described the subject matter of the present disclosure in detailand by reference to specific embodiments thereof, it is noted that thevarious details disclosed herein should not be taken to imply that thesedetails relate to elements that are essential components of the variousembodiments described herein, even in cases where a particular elementis illustrated in each of the drawings that accompany the presentdescription. Further, it will be apparent that modifications andvariations are possible without departing from the scope of the presentdisclosure, including, but not limited to, embodiments defined in theappended claims. More specifically, although some aspects of the presentdisclosure are identified herein as preferred or particularlyadvantageous, it is contemplated that the present disclosure is notnecessarily limited to these aspects.

It is noted that one or more of the following claims utilize the term“wherein” as a transitional phrase. For the purposes of defining thepresent invention, it is noted that this term is introduced in theclaims as an open-ended transitional phrase that is used to introduce arecitation of a series of characteristics of the structure and should beinterpreted in like manner as the more commonly used open-ended preambleterm “comprising.”

What is claimed is:
 1. A recreational vehicle comprising a compositelaminated panel, wherein: the composite laminated panel comprises askeletal framework, a plurality of foam core inserts, an impactresistant sheet on a first side of the composite laminated panel, aweather resistant sheet on a second side of the composite laminatedpanel, and a plurality of contained framework cells; the skeletalframework of the composite laminated panel comprises a plurality ofclosed frame sections defined by frame segments of the skeletalframework; each contained framework cell is bounded volumetrically byframe segments of a closed frame section, portions of the impactresistant sheet, and portions of the weather resistant sheet; individualones of the foam core inserts are large enough to frictionally engage atleast two parallel frame segments of a closed frame section of theskeletal framework; each contained framework cell is packed with one ormore of the foam core inserts and the foam core inserts within each cellcollectively occupy a substantial entirety of the contained frameworkcell; and the skeletal framework, the foam core inserts, the impactresistant sheet, and the weather-resistant sheet comprise a structurallyintegrated composite laminated panel, such that a collective modulus ofelasticity (MOE) of the composite laminated panel comprises moduluscomponents that are attributable to the skeletal framework, the foamcore inserts, the impact resistant sheet, and the weather resistantsheet.
 2. The recreational vehicle of claim 1, wherein the collectiveMOE of the composite laminated panel is between about 6000 ksi (4×10⁴MPa) and about 10000 ksi (7×10⁴ MPa).
 3. The recreational vehicle ofclaim 1, wherein the collective MOE of the composite laminated panel is8000 ksi (5.5×10⁴ MPa)±10%.
 4. The recreational vehicle of claim 1,wherein a majority of the closed frame sections of the skeletalframework comprise a planar area of between approximately 1.5 m² andapproximately 4.5 m².
 5. The recreational vehicle of claim 1, whereinthe closed frame sections of the skeletal framework comprise a maximumplanar area of less than approximately 6.0 m².
 6. The recreationalvehicle of claim 1, wherein a majority of the closed frame sections ofthe skeletal framework comprise a planar area that exceeds approximately1.0 m².
 7. The recreational vehicle of claim 1, wherein the closed framesections of the skeletal framework comprise a maximum unsupportedlongitudinal span of less than approximately 5.0 m.
 8. The recreationalvehicle of claim 1, wherein a majority of the closed frame sections ofthe skeletal framework comprise an unsupported longitudinal span ofbetween approximately 1.5 m and approximately 4.0 m.
 9. The recreationalvehicle of claim 1, wherein a majority of the closed frame sections ofthe skeletal framework comprise a minimum unsupported longitudinal spanthat exceeds approximately 1.0 m.
 10. The recreational vehicle of claim1, wherein each of the plurality of foam core inserts comprises adensity of at least 30 kg/m³±10%.
 11. The recreational vehicle of claim1, wherein each of the plurality of foam core inserts comprises adensity of between about 30 kg/m³±10% and about 50 kg/m³±10%.
 12. Therecreational vehicle of claim 1, wherein each of the plurality of foamcore inserts frictionally engages at least two pairs of parallel framesegments of a closed frame section of the skeletal framework.
 13. Therecreational vehicle of claim 1, wherein each contained framework cellis packed with a single foam core insert that occupies a substantialentirety of the contained framework cell.
 14. The recreational vehicleof claim 1, wherein each contained framework cell is packed with aplurality of foam core inserts that collectively occupy a substantialentirety of the contained framework cell.
 15. The recreational vehicleof claim 1, wherein a foam thickness defined by the one or more foamcore inserts packed in a contained framework cell is equal to a framethickness of the frame segments of the closed frame section bounding thecontained framework cell.
 16. The recreational vehicle of claim 1,wherein a foam thickness defined by the one or more foam core insertspacked in a contained framework cell is greater than or less than aframe thickness of the frame segments of the closed frame sectionbounding the contained framework cell.
 17. The recreational vehicle ofclaim 1, wherein the impact resistant sheet and the weather resistantsheet account for less than 20% of a total composite laminated panelthickness.
 18. The recreational vehicle of claim 1, wherein the weatherresistant sheet is characterized by: an average sheet thickness that isless than an average sheet thickness of the impact resistant sheet; andan area density that is less than 50% of an area density of the impactresistant sheet.
 19. The recreational vehicle of claim 18, wherein: thesheet thickness of the impact resistant sheet is 4.00 mm±20%; the sheetthickness of the weather resistant sheet is 2.7 mm±10%; the area densityof the impact resistant sheet is 2850 g/m²±10%; and the area density ofthe weather resistant sheet is 1000 g/m²±10%.
 20. The recreationalvehicle of claim 1, wherein: the impact resistant sheet and the weatherresistant sheet are fiberglass reinforced polymer sheets; the fibercontent of the impact resistant sheet and the weather resistant sheet isbetween about 35 wt. % and about 70 wt. % and impact resistant sheetcomprises a greater fiber content than the weather resistant sheet; andthe impact resistant sheet and the weather resistant sheet define afiber content A, representing a difference between a fiber wt. % contentof the impact resistant sheet and a fiber wt. % content of the weatherresistant sheet that is at least 20 wt. %.
 21. The recreational vehicleof claim 1, wherein: the impact resistant sheet and the weatherresistant sheet are fiberglass reinforced polymer sheets; the impactresistant sheet comprises a fiber content of about 60%; and the weatherresistant sheet comprises a fiber content of about 40%.
 22. Arecreational vehicle comprising a composite laminated panel, wherein:the composite laminated panel comprises a foam core insert, an impactresistant sheet on a first side of the composite laminated panel, aweather resistant sheet on a second side of the composite laminatedpanel, and a structural adhesive; the structural adhesive is arranged tobond the foam core insert, the impact resistant sheet, and theweather-resistant sheet as a structurally integrated composite laminatedpanel; each of the plurality of foam core inserts comprises a density ofat least 30 kg/m³±10%; the impact resistant sheet and the weatherresistant sheet account for less than 20% of the total compositelaminated panel thickness; the weather resistant sheet is characterizedby an average sheet thickness that is less than an average sheetthickness of the impact resistant sheet and an area density that is lessthan 50% of an area density of the impact resistant sheet; the sheetthickness of the impact resistant sheet is 4.00 mm±20%; the sheetthickness of the weather resistant sheet is 2.7 mm±10%; the area densityof the impact resistant sheet is 2850 g/m²±10%; the area density of theweather resistant sheet is 1000 g/m²±10%; the impact resistant sheet andthe weather resistant sheet are fiberglass reinforced polymer sheets;the fiber content of the impact resistant sheet and the weatherresistant sheet is between about 35 wt. % and about 70 wt. % and theimpact resistant sheet comprises a greater fiber content than theweather resistant sheet; and the impact resistant sheet and the weatherresistant sheet define a fiber content A, representing a differencebetween a fiber wt. % content of the impact resistant sheet and a fiberwt. % content of the weather resistant sheet that is at least 20 wt. %.